Preconnectorized Distribution Cable Assembly Using a Pull String
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Solution Overview
Problem
The high labor and cost associated with deploying multi-fiber cable networks in data centers, particularly in cabling installation, are significant challenges due to the complexity and size of modern data center infrastructure, which requires efficient and cost-effective pre-engineering of fiber optic components.
Innovation Solution
A method of manufacturing a distribution cable assembly involves feeding a pull string through a jacket of a distribution cable, attaching cable subunits to the string, and pulling them through the jacket to exterior openings, with preconnectorized components for easy installation, and using a junction shell to secure the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multi-fiber cable networks are deployed using traditional on-site connectorization methods, then installation flexibility is maintained, but labor costs and installation time increase significantly
Solution Approach 1:
The cable subunits are pre-connectorized at the factory before distribution to the installation site. Connectors are attached to the cable ends in advance, and the cables are tested and packaged for fast installation. This preliminary preparation eliminates time-consuming on-site connectorization work, directly reducing installation time while maintaining quality standards.
Solution Approach 2:
The multi-fiber cable is divided into multiple separate cable subunits, each containing a subset of fibers with connectors pre-attached. This segmentation allows for easier handling, routing, and installation of individual subunits compared to managing a single large multi-fiber cable bundle, thereby improving installation efficiency.
2Loss of time
If preconnectorized components are used to reduce installation time, then labor costs decrease, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process produces separate cable subunits rather than assembling a complete multi-fiber cable in one operation. Each subunit is manufactured and pre-connectorized independently, then packaged separately. This segmentation simplifies the manufacturing process by breaking down complex assembly operations into manageable, repeatable steps that can be performed on standard equipment.
Solution Approach 2:
Connectors are pre-attached to cable subunits during the manufacturing process under controlled factory conditions. This preliminary action allows for automated or semi-automated connectorization using standard equipment, managing manufacturing complexity while enabling fast installation at the site.
3Productivity
If cable subunits are pulled through the distribution cable jacket simultaneously, then installation speed increases, but the risk of cable damage increases
Solution Approach 1:
Multiple cable subunits are attached to a single pull string, combining them into one assembly unit. This allows all subunits to be pulled through the distribution cable jacket simultaneously in a single operation, increasing assembly speed while distributing the pulling force evenly across all subunits to minimize individual cable stress and damage risk.
Solution Approach 2:
The pull string acts as an intermediary mechanism that transfers pulling force from the installer to multiple cable subunits. By using a central pull string with attachment points for each subunit, the system enables coordinated movement of all subunits through the jacket, maintaining cable integrity while achieving simultaneous installation.
Data Source
AI summary
Disclosed herein are preconnectorized cable assemblies and methods of making using a pull string. One embodiment of the disclosure relates to a method of manufacturing a distribution cable assembly using a pull string fed through a jacket of a distribution cable. Subunit cables are attached to the pull string through openings in the jacket of the distribution cable, and then pulled, via the pull string, through the jacket until drawn through a distribution end opening of the jacket. Another embodiment relates to a distribution cable assembly including junction shells covering side openings in the jacket. The junction shell includes a first half shell attached to a second half shell by a fastener. The first half shell includes stops proximate ends of a side opening to fix the junction shell along an axis of the jacket.